Porous spun polymeric structures and method of making same

• US 20060261005A1
• Filed: 07/31/2006
• Published: 11/23/2006
• Est. Priority Date: 12/30/2002
• Status: Active Grant

• Current Assignee: Kinh-Luan D. Dao, Kshitij Mohan, Liem Vu, Sheng-Ping Zhong, Yem Chin
• Original Assignee: Kinh-Luan D. Dao, Kshitij Mohan, Liem Vu, Sheng-Ping Zhong, Yem Chin
• Inventors: Chin, Yem, Dao, Kinh-Luan (Lenny) D., Zhong, Sheng-ping (Samuel), Mohan, Kshitij, Vu, Liem
• Granted Patent: US 7,661,541 B2
• Time in Patent Office: Days
• US Class Current: 210/505
• CPC Class Codes: A61M 1/3633 Blood component filters, e.g. leukocyte filters
• CPC Class Codes: B01D 39/163 sintered or bonded
• CPC Class Codes: B01D 61/14 Ultrafiltration; Microfiltration
• CPC Class Codes: B01D 71/06 Organic material
• CPC Class Codes: D04H 3/05 in another pattern, e.g. zig-zag, sinusoidal D04H3/04 takes precedence
• CPC Class Codes: Y10T 156/1798 with liquid adhesive or adhesive activator applying means
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24479 including variation in thickness

Abstract

A non-woven polymeric matrix for separating leukocytes from a blood sample includes a non-woven three dimensional matrix formed from polymeric fibers having a predetermined pore volume fraction including a defined channel configuration, a predetermined pore size in the range of from about 10 μm to about 250 μm, and a plurality of connections between the plurality of fibers. The matrix is configured so as to remove at least about 98% of leukocytes from at least one unit of packed red blood cells. Methods of making and using the matrix are also provided.

Claims

1. A non-woven matrix material for use in a medical device comprising a non-woven three dimensional matrix of polymeric fibers wherein said matrix has a predetermined shape, a predetermined pore volume fraction including a defined channel configuration, a predetermined pore size, and a plurality of connections between said fibers.

3. The matrix material according to claim 1, wherein said predetermined pore volume fraction is from about 15% to about 98%.

4. The matrix material according to claim 1, wherein said defined channel configuration includes a series of substantially parallel pores.

5. The matrix according to claim 1, wherein said polymeric fibers are formed from a biocompatible thermoplastic polymer.

6. The matrix according to claim 1, wherein said polymer is selected from the group consisting of an alginate, a hyaluronic acid, a cellulose, a dextran, a pullane, a polyhyaluronic acid, a chitin, a poly(3-hydroxyalkanoate), a poly(3-hydroxyoctanoate), a poly(3-hydroxyfatty acid), a collagen, a zein, a casein, a gelatin, a gluten, a serum albumen, a polyphosphazene, poly(vinyl alcohol), a polyamide, a polyester amide, a poly(amino acid), a polyanhydride, a polyester, a polycarbonate, a polyacrylate, a polyalkylene, a polyacrylamide, a polyalkylene glycol, a polyalkylene oxide, a polyalkylene terephthalate, a polyortho ester, a polyvinyl ether, a polyvinyl ester, a polyvinyl halide, a polyvinyl pyrrolidone, a polylactide, a polyglyxolide, a polysiloxane, a polycaprolactone, a polyhydroxybutrate, a polyurethane, a poly a-hydroxy acid, a poly L-lactic acid, a polyglycolic acid, a styrene isobutylstyrene block polymer and blends and copolymers thereof.

7. The matrix according to claim 1, wherein said matrix has a pore volume fraction of from about 15% to about 90%.

8. The matrix according to claim 1, wherein said matrix has a pore size of from about 5 microns to about 500 microns.

9. The matrix according to claim 1, wherein said matrix has a pore size of from about 50 microns to about 150 microns.

10. The matrix according to claim 1, wherein said pores are arranged substantially continuously throughout a depth of said matrix and are substantially parallel with one another.

11. The matrix according to claim 1, wherein said pores are arranged substantially discontinuously throughout a depth of said matrix and are substantially parallel with one another.

12. The matrix according to claim 1, wherein said polymeric fibers possess an average diameter of from about 1 micron to about 40 microns.

13. The matrix according to claim 1, wherein said polymeric fibers possess an average diameter of from about 5 microns to about 15 microns.

14. The matrix according to claim 1, wherein said matrix is at least partially degradable having a predetermined rate of degradation.

2. A non-woven matrix material for use in a medical device comprising a non-woven three dimensional matrix wherein said matrix is formed by a method of selectively generating a uniform or varied micro-architecture within the three dimensional non-woven matrix, comprising the steps of:

admixing at least one fiber forming polymer with a compatible solvent to form a flowable polymer mixture;

applying at least one fiber formed from said polymer mixture to a moveable table capable of motion in a first plane (x), a second plane (y) perpendicular to said first plane, and a third plane (z) perpendicular to said first plane (x) and said second plane (y); and

controlling movement of at least said table so as to form a three dimensional non-woven matrix of fibers having a predetermined pore volume fraction including a defined channel configuration, a predetermined pore size, and a plurality of connections between said fibers.

15. A non-woven polymeric matrix for separating leukocytes from a blood sample, said matrix having a first upstream side and a second downstream side, and comprising:

a non-woven three dimensional matrix formed from polymeric fibers having a diameter of from about 5 μ

m to about 15 μ

m, the matrix having a predetermined pore volume fraction including a defined channel configuration, a predetermined pore size in the range of from about 10 μ

m to about 250 μ

m, a plurality of connections between said plurality of fibers, and being configured so as to remove at least about 98% of leukocytes from at least one unit of packed red blood cells.

16. The matrix according to claim 15, wherein said matrix further comprises a therapeutic agent.

17. The matrix according to claim 16, wherein said therapeutic agent is an anticoagulant.

18. The matrix according to claim 15, wherein said pores are arranged substantially parallel with a flow of flood therethrough.

19. The matrix according to claim 15, wherein said pores are arranged substantially non-parallel with a flow of blood therethrough.

20. The matrix according to claim 15, wherein each of said pores runs substantially continuously from a first upstream side of said matrix to a second downstream side of said matrix.

21. The matrix according to claim 15, wherein each of said pores runs substantially discontinuously from a first upstream side of said matrix to a second downstream side of said matrix.